Surgical tray corner protector

ABSTRACT

A surgical tray corner protector includes a support base, a side wall extending along an edge of the support base, and a plurality of apertures extending through the support base to form a tray support surface, providing improved drainage and air flow.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a continuation of U.S. application Ser. No.11/950,246 entitled “Surgical Tray Corner Protector” filed Dec. 4, 2007by S. Curnow and T. Ahrenholtz, which is a continuation of U.S.application Ser. No. 11/779,089 entitled “Surgical Tray CornerProtector” filed Jul. 17, 2007 by S. Curnow and T. Ahrenholtz, which isa continuation of PCT Application No. PCT/US2006/030297 filed Aug. 2,2006, which claims the benefit of U.S. Provisional Application No.60/705,245 filed Aug. 3, 2005.

INCORPORATION BY REFERENCE

The aforementioned U.S. application Ser. No. 11/950,246, U.S.application Ser. No. 11/779,089, PCT Application No. PCT/US2006/030297and U.S. Provisional Application No. 60/705,245 are hereby incorporatedby reference in their entirety.

BACKGROUND

This invention relates to a corner protector for a surgical tray. Morespecifically, this invention relates to a surgical tray corner protectorcomprising a base, a side wall which extends from an outer edge of thebase, and support members extending from the base to form a tray supportsurface, providing improved drainage and air flow.

In hospitals, surgery centers, and other healthcare facilities, surgicalinstruments must be sterilized prior to use. Normally, surgicalinstruments are placed in a surgical tray, which is wrapped in asterilization wrap to protect the instruments from subsequentcontamination. The wrapped surgical tray is then inserted into anautoclave and sterilized.

After sterilization, the wrapped tray is placed on a storage shelf orcart until it is needed for a surgical procedure. When the surgicalinstrument sterilization tray is needed, it is delivered to theoperating room. Before the surgical tray is unwrapped, the integrity ofthe sterilization wrap is inspected to ensure that it does not containany rips, tears or holes. If the wrap is compromised, the instrumentsare considered contaminated and can not be used.

Most sterilization wrap is susceptible to tearing and ripping. Handlingby hospital staff is the primary cause of ripping of sterilization wrapon a surgical tray. Many of the surgical trays used in healthcarefacilities are heavy and/or have sharp corners. When the wrappedsurgical tray is slid across a surface, instead of being directlylifted, the corners of the surgical tray can puncture the wrap, thusdestroying the sterile environment in which the surgical instruments arestored.

If the sterilization wrap on a surgical tray is torn, the surgicalinstruments must be rewrapped and sterilized again, which results inreprocessing costs and takes up staff time. In addition, surgicalprocedures may consequently be delayed. Thus, there is a need in the artfor a surgical tray corner protector that will prevent sterilizationwrap surrounding a sterile surgical tray from being ripped or torn bythe corners of the tray, and, therefore, rendering the surgicalinstruments unsterile.

SUMMARY

The present invention prevents the sterilization wrap surrounding asterile surgical tray from being compromised by rips and tears duringtransportation and storage. The present invention is a corner protectorconfigured to be positioned against a corner of a surgical tray. Thecorner protector comprises a support base, a side wall extending alongan edge of the support base and having an inner surface and an outersurface, and a plurality of apertures extending through the supportbase. The support base and side wall are composed of a medical gradepolymeric material and are configured to receive a corner of thesurgical tray such that the support base contacts a bottom panel of thesurgical tray and the inner surface of the side wall is positionedadjacent to a side panel of the surgical tray to form a protectivebarrier around the corner of the surgical tray.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of a first embodiment of a surgicaltray corner protector.

FIG. 2 is a bottom perspective view of the surgical tray cornerprotector of FIG. 1.

FIG. 3A is a top view of the surgical tray corner protector of FIGS.1-2.

FIG. 3B is a side view of the surgical tray corner protector of FIGS.1-2.

FIG. 3C is a bottom view of the surgical tray corner protector of FIGS.1-2.

FIG. 3D is a top perspective view of an alternative embodiment of asurgical tray corner protector.

FIG. 4 is side perspective view of a surgical tray fitted with cornerprotectors.

DETAILED DESCRIPTION

FIG. 1 is a top perspective view of surgical tray corner protector 10.Surgical tray corner protector 10 includes base 12, side walls 14A-14B,center support rib 16, side support ribs 18A-18D and 18A′-18D′, anddrainage apertures 20.

In the exemplary embodiment shown in FIG. 1, surgical tray cornerprotector 10 has a generally square shape. Side wall 14A extends from afirst edge of base 12 and side wall 14B extends from a second edge ofbase 12. Side walls 14A-14B meet at a corner of surgical tray cornerprotector 10, and are used to position surgical tray corner protector 10against a corner of a surgical instrument sterilization tray (not shownin FIG. 1).

Center support rib 16 extends from base 12 and runs diagonally from thejunction of vertical side walls 14A-14B to the opposite corner of base12. Side support ribs 18A-18D and 18A′-18D′ also extend from base 12 andfan outward from center support rib 16. As shown in FIG. 1, four sidesupport ribs 18A-18D are located on a first side of center support rib16 and four side support ribs 18A′-18D′ are located on a second side ofcenter support rib 16. Center support rib 16 and side support ribs18A-18D and 18A′-18D′ form about a 45 degree angle with respect to eachother. However, surgical tray corner protector 10 may comprise anynumber of central support ribs 16 and/or side support ribs 18A-18D and18A′-18D′, which may form varying angles with respect to each other.

In an exemplary embodiment, center support rib 16 and side support ribs18A-18D and 18A′-18D′ are each about 0.375 inches in width. The heightof center support rib 16 gradually increases as center support rib 16extends from the junction of vertical side walls 14A-14B. In addition,the height of side support ribs 18A-18D and 18A′-18D′ also increases asside support ribs 18A-18D and 18A′-18D′ extend from center support rib16. In an exemplary embodiment, center support rib 16 has a length ofabout 4.244 inches and a height which increases from about 0.070 inchesto about 0.269 inches. Side support ribs 18A and 18A′ have a length ofabout 2.132 inches and a height which increases from about 0.208 inchesto about 0.269 inches. Side support ribs 18B and 18B′ have a length ofabout 1.607 inches and a height which increases from about 0.162 inchesto about 0.269 inches. Side support ribs 18C and 18C′ have a length ofabout 1.082 inches and a height which increases from about 0.116 inchesto about 0.269 inches. Finally, in the exemplary embodiment shown inFIG. 1, side support ribs 18D and 18D′ have a length of about 0.557inches and a height which increases from about 0.070 inches to about0.269 inches.

Center support rib 16 and side support ribs 18A-18D and 18A′-18D′ definea support surface, which supports the weight of a surgical instrumentsterilization tray and elevates the surgical tray from base 12. Thisprevents moisture from accumulating between the bottom surface of thesurgical tray and base 12 during the sterilization process in theautoclave. In the exemplary embodiment shown, the heights of the ribsare tapered in a configuration that forms a support surface for asurgical tray in a horizontal plane, while base 12 tilts at an anglewith respect to the horizontal plane. This allows moisture to drainalong the angle of base 12. Also, in an exemplary embodiment, centersupport rib 16 and side support ribs 18A-18D and 18A′-18D′ are not incontact with each other, which further reduces the concern of moistureretention and improves the air circulation during the drying process.

Although the support members of surgical tray corner protector 10 havebeen described and shown as ribs, it should be understood that othersuitable supporting structures are also possible for supporting asurgical tray above the surface of base 12.

In the exemplary embodiment shown in FIG. 1, drainage apertures 20 areinterposed between side support ribs 18A-18D and 18A′-18D′ and extendthrough base 12. Drainage apertures 20 allow water to drain away fromthe surgical tray and improve air circulation, which aids in the dryingprocess. In the exemplary embodiment shown in FIG. 1, corner protector10 has thirty drainage apertures, which are positioned in rows betweenside support ribs 18A-18D and 18A′-18D′. However, the present inventionmay have any number of drainage apertures 20, which may form variousconfigurations.

Surgical tray corner protector 10 is reusable and may be comprised, forexample, of any suitable medical-grade polymeric material, such assilicone (40 Shore A Durometer Millable Silicone, in particular). Thistype of fluid-impermeable material further aids the ability of surgicaltray corner protector 10 to resist the accumulation and retention ofmoisture, and allows surgical tray corner protector 10 to be reusedmultiple times without degradation of the material of the cornerprotector.

FIG. 2 is a bottom perspective view of surgical tray corner protector10, which includes base 12, vertical side walls 14A-14B, drainageapertures 20, center support rib 22, and side support ribs 24A-24D and24A′-24D′.

As described with respect to FIG. 1, vertical side wall 14A extends froma first edge of base 12 and vertical side wall 14B extends from a secondedge of base 12. In an exemplary embodiment, center support rib 22 andside support ribs 24A-24D and 24A′-24D′ on the bottom surface of base 12are substantially aligned with respect to center support rib 16 and sidesupport ribs 18A-18D and 18A′-18D′ on the top surface of base 12 (shownin FIG. 1) and in effect form a mirror image of each other (althoughthis correspondence is not necessary in all embodiments). Center supportrib 22 and side support ribs 24A-24D and 24A′-24D′ are also each about0.375 inches wide and are not in contact with each other in an exemplaryembodiment.

In contrast to center support rib 16, the height of center support rib22 gradually decreases as center support rib 22 extends outward from thejunction of vertical side walls 14A-14B. In addition, the height of sidesupport ribs 18A-18D and 18A′-18D′ also decreases as side support ribs24A-24D and 24A′-24D′ extend outward from center support rib 22. In theexemplary embodiment, center support rib 22 has a length of about 4.244inches and a height which decreases from about 0.269 inches to about0.070 inches. Side support ribs 24A and 24A′ have a length of about2.132 inches and a height which decreases from about 0.269 inches toabout 0.208 inches. Side support ribs 24B and 24B′ have a length ofabout 1.607 inches and a height which decreases from about 0.269 inchesto about 0.162 inches. Side support ribs 24C and 24C′ have a length ofabout 1.082 inches and a height which decreases from about 0.269 inchesto about 0.116 inches. Finally, in the exemplary embodiment shown inFIG. 2, side support ribs 24D and 24D′ have a length of about 0.557inches and a height which decreases from about 0.269 inches to about0.070 inches.

Center support rib 22 and side support ribs 24A-24D and 24A′-24D′ definea support surface, which elevates corner protector 10 from a surface onwhich it is resting. This increases air flow and prevents moisture fromaccumulating between the bottom side of base 12 and the surface on whichcorner protector 10 is resting during the sterilization process in theautoclave. In an exemplary embodiment, the heights of the ribs aretapered in a configuration that forms the support surface in ahorizontal plane, while base 12 tilts at an angle with respect to thehorizontal plane. This allows moisture to drain along the angle of base12. Also, in an exemplary embodiment, the plane of the bottom supportsurface (defined by center support rib 22 and side support ribs 24A-24Dand 24A′-24D′ shown in FIG. 2) is parallel to the plane of the topsupport surface (defined by center support rib 16 and side support ribs18A-18D and 18A′-18D′ shown in FIG. 1).

FIG. 3A is a top view of surgical tray corner protector 10, whichillustrates exemplary dimensions of surgical tray corner protector 10.As described with respect to FIG. 1, in one exemplary embodiment, cornerprotector 10 has a generally square shape (although other shapes arecontemplated in other embodiments, such as a generally rounded shape foran embodiment designed to be used with surgical trays having roundedcorners). Corner protector 10 has a length of about 3 inches, asrepresented by line A, and a width of about 3 inches, as represented byline B. In addition, in the exemplary embodiment, as represented by lineC, the distance between the radii of drainage apertures 20, which areadjacent to each other, is about 0.525 inches.

FIG. 3B is a side view of surgical tray corner protector 10, whichillustrates exemplary dimensions of surgical tray corner protector 10.In the exemplary embodiment shown, vertical side wall 14A tapers from aheight of 1 inch at its highest point, which is represented by line D,(and at which it adjoins to vertical side wall 14B, as shown in FIG. 1)to a height of 0.375 inches at its lowest point.

FIG. 3C is a bottom view of surgical tray corner protector 10, whichillustrates exemplary dimensions of surgical tray corner protector 10.In the exemplary embodiment shown, thirty drainage apertures 20 areinterposed between side support ribs 24A-24D and 24A′-24D′. As such,five rows of drainage apertures 20 are formed on either side of centersupport rib 22. As represented by line E, in a first row containing fivedrainage apertures 20, the distance from a first side of the firstdrainage aperture 20 to a first side of the fifth drainage aperture 20is about 2.132 inches. As represented by line F, in a second rowcontaining four drainage apertures 20, the distance from a first side ofthe first drainage aperture 20 to a first side of the fourth drainageaperture 20 is about 1.607 inches. As represented by line G, in a thirdrow containing three drainage apertures 20, the distance from a firstside of the first drainage aperture 20 to a first side of the thirddrainage aperture 20 is about 1.082 inches. As represented by line H, ina fourth row containing two drainage apertures 20, the distance from afirst side of the first drainage aperture 20 to a first side of thesecond drainage aperture 20 is about 0.557 inches. The fifth rowcontains only one drainage aperture 20.

FIG. 3D is a top perspective view of surgical tray corner protector 30according to an alternative embodiment. Corner protector 30 includesbase 32, side walls 34A and 34B, center support rib 36, side supportribs 38, and apertures 40, similar to the features associated withcorner protector 10 described above. The bottom of corner protector 30may be formed with features that are similar to the top of cornerprotector 30 in an exemplary embodiment. Corner protector 30 alsoincludes additional sloped support ribs 42 adjacent side walls 34A and34B, with a portion of sloped support ribs 42 extending up at least partof side walls 34A and 34B. This embodiment is particularly appropriatefor use with surgical trays that have rounded sides. The radii of slopedsupport ribs 42 can be adjusted to correspond to the curvature of thesides of a particular shape of surgical tray, so that corner protector30 provides a snug fit against the sides of the surgical tray. Otherconfigurations of ribs or other support members may also be designed inorder to provide a desired fit with a surgical tray.

FIG. 4 is side perspective view of surgical tray 26 fitted with cornerprotectors 10, which include side walls 14A-14B. Surgical tray 26 hassquare corners, and is therefore fitted with corner protectors 10, whichalso have a generally square shape. However, the present invention mayalso be configured for use with surgical trays which have circular orother shaped corners. Although surgical tray 26 is fitted with fourcorner protectors 10, only three corner protectors 10 are visible fromthis perspective.

Side walls 14A-14B assist in properly positioning surgical tray 26 oncorner protectors 10. Side walls 14A-14B wrap around the horizontalwalls at each corner of surgical tray 26. As surgical tray 26 rests oncorner protectors 10, surgical tray 26 is elevated from the bases ofcorner protectors 10. This reduces the concern of moisture retention andimproves air circulation during the drying process.

Corner protectors 10 create a protective barrier between the corners ofsurgical tray 26 and sterilization wrap, which is susceptible to tearingand ripping. As a result, after surgical tray 26 is wrapped andsterilized, corner protectors 10 will prevent the corners of surgicaltray 24 from puncturing the plastic wrap during transportation andstorage. The sterile environment in which the surgical instruments arestored is therefore maintained.

Although the present invention has been described with reference topreferred embodiments, workers skilled in the art will recognize thatchanges may be made in form and detail without departing from the spiritand scope of the invention.

1. A sterilized surgical tray system, comprising: a surgical tray havinga plurality of corners; a plurality of corner protectors composed ofmedical grade silicone material, each corner protector comprising: asupport base having a plurality of apertures extending therethrough; anda side wall extending along an edge of the support base on only twosides of the edge of the support base, the side wall having an innersurface and an outer surface, with the inner surface of the side walland a top surface of the support base together forming a tray receivinginterface; and sterilization wrap covering the surgical tray and theplurality of corner protectors; wherein each corner protector ispositioned at one of the corners of the surgical tray such that thesupport base contacts a bottom panel of the surgical tray and the innersurface of the side wall is positioned adjacent to a side panel of thesurgical tray to form a protective barrier between the corner of thesurgical tray and the sterilization wrap.
 2. The sterilized surgicaltray system of claim 1, wherein the support base comprises a pluralityof support members extending from the top surface thereof.
 3. Thesterilized surgical tray system of claim 1, wherein the surgical traycomprises four corners.
 4. The sterilized surgical tray system of claim1, wherein each corner has a generally square shape.
 5. The sterilizedsurgical tray system of claim 4, wherein each corner protector has agenerally square shape.